The battery manufacturing industry, exemplified by pure electric vehicles and hybrid vehicles, is an emerging sector. Among these, the power battery is one of the key technologies for electric vehicles. The battery’s capacity and output efficiency determine the vehicle’s range and performance. At the same time, the quality and safety of power batteries are issues of concern for both the industry and society.
The Challenges of Power Battery Welding: Inevitable Defects
The manufacturing of power batteries involves numerous processes, many of which require laser welding to complete, such as the explosion-proof valve, tabs, and battery cover. Although laser welding offers high processing efficiency, minimal welding deformation, and a high degree of automation, the stability of welding quality remains a significant challenge due to the materials used, primarily aluminum alloy and copper.
Battery Welding Processes
Explosion-proof Valve Welding
Battery Pack module Welding
This process requires that the explosion-proof
valve and the cover plate are completely sealed
, with no missed welds, weak welds, or misaligned welds that could compromise the seal.
This involves welding copper sheets to aluminum materials. Due to the different welding properties of these materials and the tendency of thin sheets to deform during welding, weak welds can easily occur, resulting in poor weld structures.
This is an important process affecting the output efficiency of the battery pack. The challenge lies in ensuring sufficient welding depth and strength.
These welding processes often result in defects that are difficult to detect, posing quality risks and ongoing challenges for manufacturers.
ALPAS-WDD effectively detects defects in laser welding by obtaining real-time quality status of the product’s laser welding and analyzing it through the system. This system prevents defective products from progressing to the next production stage, thereby improving product yield, reducing the burden on inspection processes, and enhancing production efficiency. It provides an excellent solution for process monitoring and quality assurance in laser welding.
LFS and WDD Combination: A Comprehensive Solution for Laser Welding Quality Inspection and Process Monitoring
Additionally, in the welding of battery modules, the alignment of multiple batteries side by side presents a significant issue in maintaining consistent welding focal distance during the laser welding process. LFS introduced by Diligine can accurately measure the welding area online, effectively meeting welding efficiency requirements while greatly reducing errors caused by off-axis or secondary movement measurements. This provides a real-time detection solution for focus measurement in production lines.